So in my quest to build the quietest steering system, I have had a chance to try both major bolt-on power steering cooler kits available for the TJ. There is a lot of opinion mixed in below, you're welcome to discuss and challenge anything.
The first kit was installed at the same time as ram assist, and is the Black Magic Brakes -8 TJ Steering Cooler Kit w/V-Bar Bracket, Hose and Fittings, which came as a part of the ram assist kit. Link:
https://www.shop.blackmagicbrakes.c...ar-Bracket-Hose-and-Fittings-8-COOLER-KIT.htm
This BMB kit consists of a 14" Derale heat sink cooler (Derale 13253) that has additional custom machining to get it to fit in front of the grille V-bar, mounting in front and roughly centered to the condenser. It comes with bracketry, hardware, hose, and fittings necessary to complete the job.
The second cooler I installed, replacing the BMB cooler, was the PSC MBC100 - 19 Row Plate & Fin Fluid Cooler with Mounting Bracket Kit for 1997-2006 Jeep TJ/LJ. This is a standalone kit that can be bought with one or two coolers (the second being for the transmission). Link:
https://www.pscmotorsports.com/psc-mbc100.html
This kit uses either one or two Derale 18 row Series 8000 Plate and Fin coolers (Derale 33503) for the power steering and/or transmission coolers. The kit consists of a piece of 1/8" stainless steel that has been cut and drilled to mount two coolers side by side. The plate replaces the V-bar in the radiator. Connections are made by simply slipping the hose onto the coolers and using a worm drive clamp to secure.
So which one is better? Keep scrolling for an item by item comparison:
Installation:
Installation difficulty is about the same for both kits. In either kit, you will have to remove the top radiator screws, loosen the lower, and lean the radiator and condenser back against the fan. For the BMB cooler, you have to remove the driver's headlamp. It's not necessary for the PSC kit, but a big help. The most difficult part of the BMB kit is trying to line up all the fasteners for the mounting. The PSC kit is quite straightforward except for one exceptionally frustrating screw - the one at the bottom of the v-bar.
The PSC kit is easier to plumb as you merely stick a hose over the tube and fasteners it with a worm drive clamp, but the BMB provides more flexibility in hose routing.
Performance:
The PSC plate and fin cooler seems to significantly outperform the BMB heat sink cooler, though I don't have hard data to back up this claim. With the BMB cooler, the lines could get very hot to the touch, and seem much cooler with the PSC cooler. The PSC cooler (per Derale) is rated to 20,000 BTU/hr of max heat rejection, meaning there is a massive amount of cooling capacity. Derale does not rate their heat sink coolers.
Versatility:
The PSC cooler has the capability to mount two coolers side by side, meaning installing a power steering and transmission cooler simultaneously is super easy. PSC doesn't make this claim, but I strongly suspect you could mount an engine oil cooler kit based on the Derale 33603 in lieu of one of the regular coolers. (More detail later.) The BMB cooler has a lot more options for plumbing, meaning you can run your hoses however you like.
Note: See notes from Blaine below about the transmission cooler being undersized.
Fluid flow restriction:
I have no data to back this up but I believe the BMB wins here. The BMB kit is designed to use 1/2" ID hose (-8AN) everywhere, but the PSC kit is only designed for 3/8" (-6AN). The BMB heat sink cooler also features no small channels or flow redirection, so theoretically the BMB wins here. (However, replacing the PSC Derale 33503 with a 33603 might turn the tables. More detail later.)
Note: See notes from Blaine below about fluid flow being inadequate.
Ease of bleeding:
The PSC kit wins here. Since the cooler mounts vertically, no significant air gets trapped in the cooler itself. The horizontal BMB cooler traps air, and must be turned sideways to fully bleed.
Cost:
The PSC wins here hands down. The single PSC cooler kit is $125 (add $65 for a second Derale cooler, or buy one for $52.) The BMB kit is $380. So the PSC kit is 1/3 the cost of the BMB kit.
Durability:
BMB probably wins this one. The heat sink coolers are tough. Rocks, sticks, and other mishaps are unlikely to cause a failure. If it would break your A/C condenser, chances are it would damage a PSC cooler.
Corrosion potential:
Both the BMB and the PSC kit use stainless steel mounting brackets and aluminum coolers. The BMB doesn't actually hard mount to any carbon steel but just rests in place. The PSC bolts to the carbon steel grille. Based on this, I suspect the PSC kit has a somewhat higher potential of causing galvanic corrosion.
Airflow restriction:
This one I'm not 100% sure about, and this is pure speculation. I think the PSC cooler adds a bit more overall airflow restriction to the condenser and radiator than the BMB, but it is spread out over a larger area. I drilled three 1" holes in the lowest tab of the PSC bracket for a slight boost to airflow.
Company support:
Both companies very much stand behind their product, and I have had great experiences with both.
My personal opinion/conclusion:
I believe the PSC cooler kit, either single or dual, is a better value than the BMB cooler kit. Neither kit is bad, but I think the PSC kit seems to give more capability per unit of cost than the BMB. It does have some drawbacks, but as I will later discuss, I think some of these can be addressed.
The first kit was installed at the same time as ram assist, and is the Black Magic Brakes -8 TJ Steering Cooler Kit w/V-Bar Bracket, Hose and Fittings, which came as a part of the ram assist kit. Link:
https://www.shop.blackmagicbrakes.c...ar-Bracket-Hose-and-Fittings-8-COOLER-KIT.htm
This BMB kit consists of a 14" Derale heat sink cooler (Derale 13253) that has additional custom machining to get it to fit in front of the grille V-bar, mounting in front and roughly centered to the condenser. It comes with bracketry, hardware, hose, and fittings necessary to complete the job.
The second cooler I installed, replacing the BMB cooler, was the PSC MBC100 - 19 Row Plate & Fin Fluid Cooler with Mounting Bracket Kit for 1997-2006 Jeep TJ/LJ. This is a standalone kit that can be bought with one or two coolers (the second being for the transmission). Link:
https://www.pscmotorsports.com/psc-mbc100.html
This kit uses either one or two Derale 18 row Series 8000 Plate and Fin coolers (Derale 33503) for the power steering and/or transmission coolers. The kit consists of a piece of 1/8" stainless steel that has been cut and drilled to mount two coolers side by side. The plate replaces the V-bar in the radiator. Connections are made by simply slipping the hose onto the coolers and using a worm drive clamp to secure.
So which one is better? Keep scrolling for an item by item comparison:
Installation:
Installation difficulty is about the same for both kits. In either kit, you will have to remove the top radiator screws, loosen the lower, and lean the radiator and condenser back against the fan. For the BMB cooler, you have to remove the driver's headlamp. It's not necessary for the PSC kit, but a big help. The most difficult part of the BMB kit is trying to line up all the fasteners for the mounting. The PSC kit is quite straightforward except for one exceptionally frustrating screw - the one at the bottom of the v-bar.
The PSC kit is easier to plumb as you merely stick a hose over the tube and fasteners it with a worm drive clamp, but the BMB provides more flexibility in hose routing.
Performance:
The PSC plate and fin cooler seems to significantly outperform the BMB heat sink cooler, though I don't have hard data to back up this claim. With the BMB cooler, the lines could get very hot to the touch, and seem much cooler with the PSC cooler. The PSC cooler (per Derale) is rated to 20,000 BTU/hr of max heat rejection, meaning there is a massive amount of cooling capacity. Derale does not rate their heat sink coolers.
Versatility:
The PSC cooler has the capability to mount two coolers side by side, meaning installing a power steering and transmission cooler simultaneously is super easy. PSC doesn't make this claim, but I strongly suspect you could mount an engine oil cooler kit based on the Derale 33603 in lieu of one of the regular coolers. (More detail later.) The BMB cooler has a lot more options for plumbing, meaning you can run your hoses however you like.
Note: See notes from Blaine below about the transmission cooler being undersized.
Fluid flow restriction:
I have no data to back this up but I believe the BMB wins here. The BMB kit is designed to use 1/2" ID hose (-8AN) everywhere, but the PSC kit is only designed for 3/8" (-6AN). The BMB heat sink cooler also features no small channels or flow redirection, so theoretically the BMB wins here. (However, replacing the PSC Derale 33503 with a 33603 might turn the tables. More detail later.)
Note: See notes from Blaine below about fluid flow being inadequate.
Ease of bleeding:
The PSC kit wins here. Since the cooler mounts vertically, no significant air gets trapped in the cooler itself. The horizontal BMB cooler traps air, and must be turned sideways to fully bleed.
Cost:
The PSC wins here hands down. The single PSC cooler kit is $125 (add $65 for a second Derale cooler, or buy one for $52.) The BMB kit is $380. So the PSC kit is 1/3 the cost of the BMB kit.
Durability:
BMB probably wins this one. The heat sink coolers are tough. Rocks, sticks, and other mishaps are unlikely to cause a failure. If it would break your A/C condenser, chances are it would damage a PSC cooler.
Corrosion potential:
Both the BMB and the PSC kit use stainless steel mounting brackets and aluminum coolers. The BMB doesn't actually hard mount to any carbon steel but just rests in place. The PSC bolts to the carbon steel grille. Based on this, I suspect the PSC kit has a somewhat higher potential of causing galvanic corrosion.
Airflow restriction:
This one I'm not 100% sure about, and this is pure speculation. I think the PSC cooler adds a bit more overall airflow restriction to the condenser and radiator than the BMB, but it is spread out over a larger area. I drilled three 1" holes in the lowest tab of the PSC bracket for a slight boost to airflow.
Company support:
Both companies very much stand behind their product, and I have had great experiences with both.
My personal opinion/conclusion:
I believe the PSC cooler kit, either single or dual, is a better value than the BMB cooler kit. Neither kit is bad, but I think the PSC kit seems to give more capability per unit of cost than the BMB. It does have some drawbacks, but as I will later discuss, I think some of these can be addressed.
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